Seat trim cover assembly aid

ABSTRACT

A method of manufacturing a seat that includes the steps of attaching adjacent upholstery panels with a locator strip and attachment strip sandwiched therebetween. The attachment strip includes an enlarged edge portion that engages clips in a molded foam seat backing. At least a portion of the locator strip is torn away along a line of perforations formed therein.

TECHNICAL FIELD

The present invention relates generally to processes and designs forattaching upholstery material to a seat backing, and relates moreparticularly to such a design and process wherein a locator strip and anattachment strip are secured to adjacent pieces of upholstery materialand the attachment strip is engaged with clip retainers in the seat,allowing part of the locator strip to be torn away.

BACKGROUND OF THE INVENTION

Conventional vehicle seats generally include one or more backingmembers, and a plurality of upholstery panels positioned thereon.Various processes and designs have been developed over the years forattaching the upholstery material onto the backing. Automated methodsare known whereby the upholstery material is positioned by a machineonto the pre-formed backing material, as well as methods wherein anoperator attaches the upholstery material manually.

In one common manual technique, an operator positions the upholsterymaterial and secures the same to the backing material by sliding aretaining member attached to adjacent pieces of upholstery material intoa receiving groove in a foam cushion or backer. This process allows theupholstery to be attached to the backer relatively quickly and easily,however it is necessary to fold one of the adjacent upholstery panelsdouble, i.e. backwardly against the opposing piece of upholsterymaterial so that the operator can visually determine the appropriateorientation and positioning of the retaining member for receipt in thegroove.

In another known design, a robotic machine is utilized to positionupholstery material proximate a mold in which a formable foamingmaterial is injected, which solidifies to create the backer for theseat. The solidification of the foam material adheres to a retainingmember extending between the adjacent upholstery panels. In this design,the robotic device grasps a strip that is inserted and attached betweenthe adjacent panels, which may be tom away along a perforated line afterthe molding process is complete.

SUMMARY OF THE INVENTION

The present invention provides a design and process for attachingupholstery material to a seat cushion or backing. The design preferablyincludes a locator strip and an attachment strip secured betweenadjacent upholstery panels attached with longitudinal stitching lines.The locator strip and attachment strip may be one integral piece, orthey may be formed as separate pieces. A first stitching line preferablypenetrates both pieces of cover material as well as the locator stripand attachment strip. A second stitching line is substantially parallelto the first stitching line and preferably pierces both of the coverpanels and the locator strip, but does not pierce the attachment strip.The second stitching line is preferably positioned inboard of theattachment strip. During seat assembly, the locator strip can bemanually grasped from an exterior side of the upholstery covering, andthe material manipulated such that the attachment strip may be pushedinto a complementary groove in the seat backer. One or more clips moldedinto or otherwise attached to the backer preferably snap-fit with theattachment strip. Once positioned appropriately, the locator strip maybe tom away from the seat assembly along longitudinal perforationsformed in the strip.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectioned end view, partially in perspective of a coverattachment assembly according to a preferred embodiment of the presentinvention;

FIG. 2 is a sectioned end view, also partially in perspective of thecover assembly of FIG. 1, illustrating a locator strip in a partiallytorn position;

FIG. 3 is a sectioned side view along line A—A of FIG. 2;

FIG. 4 is a sectioned end view partially in perspective of a secondpreferred embodiment of the present invention;

FIG. 5 is a partial enlarged view of the cover attachment assembly ofFIG. 1.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIG. 1, there is shown a seat cover assembly 10 accordingto the present invention, adapted for attaching to a seat backing 12.Seat cover assembly 10 includes first and second upholstery panels 11Aand 11B. Upholstery panels 11A and 11B are joined at a seam 15 andpreferably stitched together there along via first and second stitchinglines 20 and 30. A locator strip 40 and attachment strip 50 arepreferably sandwiched between upholstery panels 11A and 11B and extendsubstantially along a length of seam 15. Locator strip 40 and attachmentstrip 50 may be formed integrally, e.g. as a single plastic extrusion,or they may be formed as individual pieces. In a preferred embodiment,locator strip 40 and attachment strip 50 are positioned adjacently;however, attachment strip 50 might be positioned on the opposite side ofone of upholstery panels 11A and 11B from locator strip 40. Locatorstrip 40 is preferably an elongate rectangular plastic piece having asubstantially uniform thickness. In a preferred embodiment firststitching line 20 pierces both of upholstery panels 11A and 11B as wellas locator strip 40 and attachment strip 50. While FIG. 1 illustrateslocator strip 40 and attachment strip 50 substantially as a uniformpiece, in alternative preferred embodiments locator strip 40 andattachment strip 50 include a region 60 that overlaps proximate firststitching line 20, as shown in FIG. 5. Thus, when seat cover assembly 10is assembled, a portion of attachment strip 50 is positioned in anoverlying relationship with a portion of locator strip 40, and firststitching line 20 is subsequently formed therethrough. Second stitchingline 30 preferably pierces both of upholstery panels 11A and 11B as wellas attachment strip 50, however, locator strip 40 preferably does notextend sufficiently far in an outboard direction between panels 11A and11B such that it is pierced by second stitching line 30. As used herein,the term “outboard” should be understood to refer to a direction towardthe edges of panels 11A and 11B that comprise seam 15, whereas “inboard”should be understood to refer to an opposite direction, i.e. away fromseam 15.

Seat backing 12 is preferably a solid piece of pre-formed foam materialwell known in the art. The present invention is contemplated for usewith pre-formed seat backings, as opposed to systems wherein a seatbacking if formed during cover assembly, such as by foaming the backingmaterial while the cover is positioned thereover. A groove 14 is formedin seat backing 12, preferably during the molding process. Alongitudinal slit 16 may be formed in groove 14, as described below. Ina preferred embodiment, an assembly worker can grasp locator strip 40and manipulate seat cover assembly 10 such that the attached portions ofupholstery panels 11A and 11B, along with attachment strip 50 can beinserted into groove 14. This step may be performed “blind,” that is bygrasping locator strip 40 from an exterior cover side of the upholsterypanels 11A and 11B, and moving attachment strip 50 to an appropriateposition, aligned with groove 14, then pushing attachment strip 50 intoplace. This step can be carried out without the need for flipping theupholstery panels such that they are doubled over to visually identifythe appropriate place for attachment strip 50.

Turning to FIG. 2, there is shown seat cover assembly 10 engaged withseat backing 12. Upon engaging cover 10 and backing 12, locator strip 40may be torn away from seam 15 along the perforations formed by firststitching line 20, rendering an aesthetically pleasing appearance to thecovered seat. Embodiments are contemplated wherein the entire strip 40is pulled free from seam 15, as well as embodiments wherein a portion ofstrip 40 remains. A plurality of perforations 41 are illustrated in FIG.2 and represent points at which locator strip 40 is longitudinallypierced by the stitches that form first stitching line 20. It should beappreciated, however, that perforations 41 need not be formed by thestitches, but could instead be formed by some other means. Attachmentstrip 50 preferably includes an arrow-shaped, barbed or otherwiseenlarged longitudinal edge portion 51 for engagement with complementaryclips in backing 12, described below. Various adhesives, epoxies, etc.may be utilized to enhance the retention of attachment strip 50 and theedges of upholstery panels 11A and 11B in groove 14.

Turning now to FIG. 3, there is shown a sectioned view of the variouscomponents of seat cover assembly 10 taken along line A—A of FIG. 2,prior to tearing locator strip 40 away from assembly 10. As illustratedin FIG. 3, first and second stitching lines 20 and 30 extendsubstantially in parallel proximate an interface of locator strip 40 andattachment strip 50. The interface of locator strip 40 and attachmentstrip 50 comprises an overlapping region 60, also shown in FIG. 5. Firststitching line 20 is preferably formed such that it pierces both oflocator strip 40 and attachment strip 50, whereas second stitching line30 preferably pierces only attachment strip 50.

Further illustrated in FIG. 3 are retention members or clips 70. In apreferred embodiment, clips 70 snap fit with enlarged edge portion 51 ofattachment strip 50, and assist in retaining attachment strip 50 in thetarget groove. Clips 70 are preferably attached to backing member 12,within groove 14, and the seat cover assembly lowered into engagementwith backing member 12, snap fitting attachment strip 50 into engagementwith clips 70. Various designs are contemplated wherein clips 70 arepositioned at varying locations along the groove in the seat backing,allowing the cover assembly 10 to be secured at selected points. Forexample, portions of vehicle seats exposed to relatively greatermechanical stress and strain may call for a relatively securely attachedcover assembly at that point, requiring one or more clips. Other regionsmay require or be better suited to a degree of play between the coveringand the backer and may thus require fewer or no clips 70.

Turning now to FIG. 4, there is shown an alternative embodiment of thepresent invention including an attachment strip 150 having analternatively shaped head 151. Many variations might be made to thedesign and structure of attachment strip 50, 150. It is generallypreferred, however, to provide a strip having a shape that facilitatesmating engagement with fasteners or clip members 70.

By providing a design having a plurality of fasteners 70, preferablyslidable relative to enlarged portion 51, 151, seat cover assembly 10can be securely attached to seat backing member 12 at a plurality ofselectable positions along a length of strip 50, 150. Moreover, asliding interface between clips 70 and attachment strip 50 provides forsome “play” between the clips 70 and secured cover assembly 10, reducingwear on the seat in some instances, and compensating for slightvariations from the prescribed fastening of the seat cover 10 to theseat backing 12 during manufacturing. Thus, where attachment strip 50,150 is not perfectly positioned relative to a particular supporting clip70, the relative position of the cover assembly 10 with respect to theseat backing 14 can be adjusted slightly without disengaging the coverassembly 10 therefrom.

Further advantages of the present design include the capacity for“two-way” assembly of seat covers with seat backing members. Forexample, because an operator can grasp locator strip 40, entry of theedges of upholstery panels 11A and 11B into groove 14, along withattachment strip 50, can be made from either of opposite sides of groove14. Variations in the design of interior upholstered members in vehiclesmakes it desirable in some instances to be able to attach the upholsterycover from different angles or sides of the groove 14.

The present description is for illustrative purposes only, and shouldnot be construed to narrow the breadth of the present invention in anyway. Thus, those skilled in the art will appreciate that variousmodifications might be made to the presently disclosed embodimentswithout departing from the spirit and scope of the invention. Otheraspects, features, and advantages will be apparent upon an examinationof the attached drawing Figures and appended claims.

1. An upholstered seat comprising: a preformed molded foam seat backinghaving a groove; a plurality of clip members attached to said seatbacking at a plurality of locations along said groove; an upholsterycovering comprising adjacent panels with aligned longitudinal edges,said panels attached with at least one stitching line positioned inboardof said edges and substantially parallel thereto; an elongate locatorstrip sandwiched between said upholstery panels and securedtherebetween, said strip having a plurality of longitudinal perforationsdefining a tear line; an elongate attachment strip proximate saidlocator strip, said attachment strip having an enlarged longitudinalportion outboard of the stitching line that is engageable with saidclips and slidable within said clips; wherein said elongate locatorstrip is tearable along said tear line to remove at least a portion ofthe locator strip from between the panels.
 2. The vehicle seat of claim1 wherein the attachment strip and locator strip are a unitary piece. 3.The vehicle seat of claim 1 wherein the perforations in said locatorstrip are formed by stitches comprising said stitching line.
 4. Thevehicle seat of claim 1 wherein the enlarged longitudinal edge portioncomprises a substantially arrow shaped cross section.
 5. The vehicleseat of claim 1 wherein the attachment strip is sandwiched between theupholstery panels and adjacent the locator strip.
 6. The vehicle seat ofclaim 1 wherein the locator strip is an elongate extruded plastic piecehaving a substantially uniform thickness.
 7. An upholstered seatcomprising: a performed molded foam seat backing having a groove; aplurality of clip members attached to said seat backing; an upholsterycovering comprising adjacent panels with aligned longitudinal edges,said panels attached with at least one stitching line positioned inboardof said edges and substantially parallel thereto; an elongate locatorstrip sandwiched between said upholstery panels and securedtherebetween; an elongate attachment strip proximate said locator strip,said attachment strip and said locator strip overlap, said attachmentstrip having an enlarged longitudinal portion outboard of the stitchingline that is engageable with said clips; wherein said elongate locatorstrip is tearable along a tear line to remove at least a portion of thelocator strip from between the panels.
 8. The vehicle seat of claim 7further including a second stitching line, said first stitching linepierces said locator strip and said attachment strip, said secondstitching line pierces only said attachment strip.